| Size Guide | M | L | XL |
| CM | 53-56 | 57-60 | 61-63 |
| Inches | 21 - 217/8 | 221/4 - 231/2 | 237/8 - 245/8 |
| US Hat Size | 65/8 - 7 | 71/8 - 75/8 | 75/8 - 77/8 |
EXPLORER
EXPLORER
** Some CAMEL options are Out of Stock - ETA for fabric arrival February 24th **

explorer Size Guide

Measuring Your Head Size
- To determine your hat size follow these 3 simple steps:
Measure the circumference around your head - approximately 12mm (1/2”) above the ears - Keep the dressmaker tape level and firm, across the temple and above the eyebrow ridges.
- Check the size chart given above.
NOTE: For in-between measurements we recommend selecting the next size up, as you don't want the annoying head pressure.
You could add a drawstring & toggle for extra security. You can also add our Chiller Fillers (foam strips) to your order. They stick under the interior elastic sweatband out of sight. This would reduce 1 hat size (1cm/0.4")
For A Perfect Fit.
If you’re on the border and worried that the next size up will be too loose, just add our custom Hat Filler’s under the front and rear elastic sweatband. They will be out of sight while you tailor your Chiller to be the perfect fit!
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The modern day Fedora. There's a reason why it's called the Explorer, this is the most travelled hat on earth. The packability and versatility are unmatched. It is hand-crafted from our premium custom Faux Suede. Think day wear, evening, beach club, weddings, lawn bowls, even relaxing by the pool! The galvanised steel wire in the brim will allow it to maintain its shape, even in the water!
Featuring a 6.5cm/2.6" brim, plaited banding, ventilation eyelets, nickel rust proof hardware, and soft elastic interior banding for a secure fit. Light-weight and durable with a 50+ UPF Sun Protection rating.
- 50+ UPF Sun Protection
- Faux Suede (No animal products)
- Instant Chill! Soakable Fabric
- 6.5cm/32.6" Brim - 11.5cm/4.5" Crown
- Packs Flat - No Fold
Fit Guide
Fit Guide
| Size Guide | M | L | XL |
| CM | 53-56 | 57-60 | 61-63 |
| Inches | 21 - 217/8 | 221/4 - 231/2 | 237/8 - 245/8 |
| US Hat Size | 65/8 - 7 | 71/8 - 75/8 | 75/8 - 77/8 |
Care Guide
Care Guide
Adjust Crown Depth
Adjust Crown Depth
All our crowns are hand turned during their production. You can customize the height and depth quite easily.
Please click the link below for more information.
Pack For Travel
Pack For Travel
You can pack Aussie Chiller Headwear flat, but please don’t fold it as you could compromise the brim.
Video tutorial below:
Shipping & Returns
Shipping & Returns
Where it's made
Where it's made
Our headwear are manufactured and produced at our factory in Burleigh Heads, Queensland, Australia. We have been doing so since 1989.

Instant Heat Relief
You can soak our headwear in cold water to provide relief during the harsh summer days. Aussie Chiller Bushie perforated hats offer excellent ventilation with many different colours and styles to choose from. Golfers everywhere are sure to find the right Aussie Chiller hat to keep them cool on the links.
Adjustable Fit
Grab the interior stretch band at the rear seam, as shown, and slide it on in this position for a dramatically tighter fit. Works well in heavy wind, or to reduce a medium to small.
Earth friendly
Stay stylish while supporting the planet! Our sustainable headwear is crafted from high-quality, Earth-friendly materials — 100% free of animal products. Whether you’re shielding from the sun or completing your outfit, this hat is designed for comfort, durability, and conscious living. Ethically made, responsibly sourced, and kind to all living beings —because looking good should never come at the planet’s expense.
People Are Asking
How do I know my size?
We strongly recommend each customer measures their head before purchasing their new hat to ensure they’re selecting the correct size.
Just like shoes and clothing sizes, everyone has a unique head shape and size, which is why we offer a range of sizing options. We also urge customers to pay close attention to size and fit description on our individual product pages to assist with their purchase.
Can I wet my hat?
All Aussie Chiller products are made to be wet. Don’t fret, wetting your new hat won’t cause water marks, mold, or that dreaded sour smell.
For more information please head over to our 'soak me' page.
How do I return an item?
For all details on return enquiries, please head over to our'returns policy'page.
How do I care for my hat?
When cared for correctly, our durable hats are designed to withstand the test of time.
The care guide underneath each product will provide tips on how to care for your new Aussie Chiller hat.
How long does shipping take?
We offer standard and express shipping options for all domestic and international orders.
Shipping times will vary depending on your location.
For further information on shipping, please head over to our 'shipping' page.
Where are they made?
All hats are made locally in Gold Coast, Australia.
Featured Reviews
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"Thank you I love my hat! Ordered my pearl Bushie Plus just before travelling to Sicily and with the swift delivery I got it in time for departure. I’m so satisfied with my hat that I will order also another modell when home again. Thank you for proving how online shopping really should be. I will recommend to anybody to go through with a purchase from Aussi Chiller."
Catrin S.
August 2025
Catrin S.
August 2025
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"The best hat I’ve ever owned! I travel a lot and was looking for a versatile packable hat for warmer weather. I explored the Aussie Chiller site and ordered the perforated Bushie based on the reviews. I’m so happy I did. I live in the northeast US and recently traveled to Key West Florida. The Bushie came out of my suitcase unscathed. Just popped it back in shape. I wore it all the time from the beach, pool, soaked it and it kept me cool in very warm weather. I’m a musician and wore it to perform. I received so many compliments. I’m going to order a solid Bushie plus for the cooler months. Thank you Aussie Chiller for a wonderful well made hat!"
John S.
September 2025
John S.
September 2025
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"Great!! So good I've got two! Comfortable, practical! Simply great"
Tom F.
December 2024
Tom F.
December 2024
Wear-All-Day Comfort
What makes Aussie Chiller different?
- Australian Made and Owned
- ‘Soak me’ fabric
- Durability and Longevity/Quality
- Cooling Technology
- UV Protection - UPF 50+
- Practical & long-lasting
- Comfort (lightweight/doesn’t overheat)
- Environmentally friendly (slow fashion)
Reviews
- AAAlexandra A.Verified BuyerI recommend this productRated 5 out of 5 stars1 month agoExplorer Hat
Absolutely love my new hat. It fits well and has been in the surf, fresh water and chlorinated pools and is still going strong. Would 100% recommend to anyone wanting a versatile hat that doesn't compromise style.
Was this helpful? - RPRachel P.Verified BuyerI recommend this productRated 4 out of 5 stars1 month agoGreat hat
I ordered the navy explorer a couple of weeks before Christmas, as a gift for my husband. Unfortunately I received a green one. However, Aussie Chiller responded very quickly to my email and managed to get the navy one out to me on Christmas eve. It was a busy time of year, mistakes happen, but how a company responds is what matters. I will definitely order from Aussie Chiller again. My husband loves his hat.
Was this helpful? - LALucas A. G.Verified BuyerI recommend this productRated 5 out of 5 stars1 month agoAwesome!
As described and stays in place particularly well
Was this helpful? - LGLeanne G.Verified BuyerI recommend this productRated 5 out of 5 stars1 month agoSo true
Couldn’t believe how lightweight and comfy that’s from a kiwi
Was this helpful? - MKmarc k.Verified BuyerI recommend this productRated 5 out of 5 stars1 month agoExcellent hat
One of the best hats ever bought get wet stays in shape.
A when it is wet keeps you even cooler.they fit true to size awesome hat for summer or winter.or just working in the garden .
Was this helpful?
The Bushie Plus
A new addition to our Aussie Chiller range. The Bushie Plus has fast become a customer favourite!